Material-independent Dimensioning of Knurled Interference Fits of arbitrary Shape

轴-毂连接经常用于传递动态力和扭矩。在大多数情况下，使用非啮合或形式闭合连接。滚花过盈配合（KIF）代表摩擦和形状闭合的组合。基于接合过程，在轴向方向上发生摩擦闭合。此外，由于滚花形状形成相关的互补件（毂或轴），因此在切向方向上发生形状闭合。KIF的重要性不断增加。但是KIF的尺寸和设计存在相当大的不安全性，因为没有像DIN 7190那样的通用指南用于圆柱形压配合。因此，该项目的主要目标是对具有任意形状的KIF进行与材料无关的尺寸标注。第一次验证设计算法的连续数值模拟以及（半）分析计算的KIF将可用。对于汽车轻量化设计概念，将研究带滚花轴的钢/铝压铸件材料组合。此外，将分析用于齿轮应用的钢/带滚花轮毂的钢材料组合。基于对过去项目的了解，结合计划的材料组合42 CrMo 4/ EN AC-46000和C45 /16 MnCr 5，为所需的目标提供了特定的材料和特定的几何基础。在这一点上，任意形状指的是后刀面节距、节距角和滚花位置的变化。为了进行可靠的静态和动态设计以及验证KIF的连续数值模拟，需要获得知识。另一个目标是加强和推广连接力和扭矩的分析计算方法。基于上述材料和几何结构特定的基础，通过以下策略确保预期的商业可用性：分析：采用分析方法设计KIF数值：任意形状轴向连接KIF的材料无关尺寸的连续数值模拟指南

Shaft-Hub-Connections are frequently used for the transmission of dynamic forces and torques. In most cases, frictionally engaged or form closed connections are used. The Knurled-Interference-Fit (KIF) represents a combination of friction and form closure. Based on the joining process a friction closure occurs in the axial direction. Additionally, a form closure occurs in the tangential direction, because of the knurled shape which is formed into the relevant complement (hub or shaft). The importance of KIFs continuously increases. But there is a considerably insecurity regarding the dimensioning and the design of KIFs, because there is no general guideline like DIN 7190 for cylindrical press-fits. Therefore, the primary aim of the project is the material-independent dimensioning of KIFs with arbitrary shape. For the first time a validated design-algorithm for the continuous numerical simulation as well as for the (semi)analytical computation of KIFs will be available. For automotive lightweight design concepts the material combination steel/aluminum pressure die casting, with knurled shafts, will be investigated. Furthermore, the material combination steel/steel with knurled hubs, for gear wheel applications, will be analyzed. Based on the knowledge of the things past project in conjunction with the planned material combinations 42CrMo4 / EN AC-46000 and C45 / 16MnCr5 the specific material and the geometry-specific basis, for the desired target is given.The arbitrary shape refers at this point to the variation of the flank pitch, the pitch angle and the position of the knurls. For a reliable static and dynamic design as well as for the validation of the continuous numerical simulation of KIFs gaining of knowledge is necessary. Another aim is the enhancement and the generalization of analytical computation approaches for the joining-force and the torque.Based on the mentioned material and geometry-specific base the prospective commercial usability is ensured by the following strategies:Analytical: Design of KIFs with analytical approachesNumerical: Guideline for the continuous numerical simulation for the material-independent dimensioning of axial joint KIFs, of arbitrary shape